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Learn how to prevent accidents involving forklift trucks with this comprehensive handbook. Discover important safety regulations, qualification requirements, and principles of stability. Understand load centers, capacity data, and how to conduct pre-shift inspections.
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Intro Have you… HEARD OF, WITNESSED, or been INVOLVED IN.. an accident involving a Forklift Truck?
Intro The term.. “ACCIDENT” Can mean many things.. It does not necessarily mean someone was injured!
Intro “Dropped Loads” or “Unintentional Contact” Is considered.. AN ACCIDENT!
Intro National Forklift Accident Statistics: 26% are tip-over. 18% are pedestrians being struck. 14% are falling loads or debris. 14% are improper personnel lifting. 7% operator drove off a loading dock. 3% operator lost control of the forklift. What percentage of these were preventable?
Intro Main contributing factors: Untrained Operators Loss of Concentration Unsafe Operation As operators, you have the greatest impact on reducing forklift accidents!
Intro FACT: Untrained people will unsafely improvise!
Page 2 Federal and State Laws Federal OSHA Regulation for Powered Industrial Trucks 29CFR1910.178 became law effective 12/01/1999. Excerpts from Federal and State Regulations are used throughout this handbook.
Page 3 For qualification, youmust complete a 4 step process: Complete classroom training and pass the written exam. Understand the operating and safety rules per the mfr. manual. Understand the site-specific safety hazards and procedures (employer). Pass a practical evaluation of the skill set required for the job.
Page 3 You must understand: All instructions, warnings, decals and precautions. How forklifts and autos differ. Location and function of all controls. Steering and maneuvering. Adjusting for restricted visibility. Fork and attachment usage & limitations. Forklift capacity or stability ratings. Pre-op forklift and site inspection requirements. Refueling and/or recharging the batteries. Prior to operating an unfamiliar model, youmust: Become familiar with the operator’s manual, all control functions, and safety devices. Document this familiarization in writing.
Page 3 To maintain qualification, youmust be: Re-evaluated every three years. Trained and evaluated if assigned to operate an entirely different classification of forklift. Retrained if involved in an accident/ near-miss or observed operating unsafely.
Page 4 Forklift Classifications Powered Industrial Trucks (Forklifts) are divided into various classification types.
Page 5 Principles of Stability Counterweighted forklifts operate on the simple principle of lever and fulcrum, which has an effect similar to a teeter-totter. The counterweight (rear) is used to counterbalance the load on the forks. The Pivot Point (or fulcrum) is the front drive axle. By adjusting the fulcrum closer to the load, you are able to pick up additional weight without adding additional counterweight.
Page 5 Definitions Center of gravity (COG): The point on an object at which all the object’s weight can be considered to be concentrated. Combined COG: The COG of the forklift and the COG of the load being carried.
Page 6 Lift is stable side to side, CCG is low and within the triangle. CG CCG CG
Page 6 Lift is less stable, CCG is high and is now top heavy. CG CCG CG CG CCG CG
CG CCG CG CG CCG CG Page 6 Lift is even more unstable, CCG is very high.
CG CCG CG CG CCG CG Page 6 This forward tilt will cause the truck to tip forward!
CG CCG CG CG CCG CG Page 6 Tilting the load backward affects the side stability:
LOAD LOAD CCG LOAD CCG CCG Page 6 Any lateral or sideways movement of an elevated load has the potential to cause….
LOAD LOAD CCG LOAD CCG CCG Page 6 A sideways tip-over………… because the CCG will move outside the stability triangle.
Page 6 To ensure forklift stability, youmust: Never exceed the load rating charts. Ensure the forklift is level prior to lifting. Recognize that vertical lifting of loads changes the stability. Move the forklift incrementally (slowly & slightly) with elevated forks. Never turn when the forks are elevated more than a few feet off the ground. Never travel when the forks are elevated higher than the minimum required to clear obstacles.
Page 7 Load Center Load center is the distance from the load backrest to the center of the load. Most are rated using a 24” load center. This assumes the load is evenly distributed on the forks. A 4’ x 4’ pallet has a 24” load center As the load center increases or moves farther away from the load backrest, the capacity of the forklift will decrease.
Page 8 Load Center Typical rating capacities at various load center configurations. Remember your load center can change. Different capacities at various load centers are shown on your forklift tare plate and usually in your operators manual.
POUNDS “ “ “ “ “ “ “ “ “ “ “ “ Page 7
Page 8 Capacity Data Maximum capacity means maximum. Ratings include all items positioned on your forks. Load chart rating data is 100% of the forklift capacity. There is no built-in safety buffer.
Page 9 Pre-Shift Inspection Prior to each shift, a pre-start inspection must be completed. Defects found affecting safe operation must be immediately reported and all corrections must be made prior to operation
Page 9 Function check, you must check: For loose objects hindering movement. Normal operating temperatures and gauges, instruments, and all lights work properly. Horn and backup alarm function properly. Braking (including emergency) in forward and reverse. Steering and control levers for full function and range.
Page 10 Prior to operating, you must check: Poor or slippery surface conditions. Overhead and/or underground hazards. Pedestrian traffic (and as you are operating). Narrow aisles. Hazardous (classified) locations. Ramps/sloped surfaces. Potential exhaust buildup.
Page 13 Traveling & turning, you must : Wear appropriate clothing and P. P. E. Use special care when traveling unloaded. Observe all traffic rules, speed limits. Maintain 3 truck lengths from vehicle ahead. Carry load at height only to clear obstacles. Yield to pedestrians, emergency vehicles. Not pass at intersections, blind spots, or other dangerous locations. Slow down and sound the horn where visibility is obstructed or reduced.
Page 13 Traveling & turning, you must : Travel in reverse, if vision is obstructed. Ensure surface will support weight of forklift. Always travel at appropriate speeds. Never allow stunt driving or horseplay. Turn in a slow, smooth sweeping motion. Travel with only one foot on the dead-man pedal (stand-up). Fully retract the reach before traveling. Ensure steering casters are pointed in the correct direction prior to beginning travel. Wear the seat belt if provided Be alert for other vehicles/pedestrians. NOTE: Jobsites or facilities are busy with heavy worker and equipment traffic during peak times.
Page 13 When stopping, you must: Anticipate your stops and begin to slow down in advance. Never suddenly stop to discharge the load. Use plugging (directional reversal) to stop the momentum (stand-up & pallet jacks). To ensure safe stopping, you must consider: Traveling speed of the forklift. Combined weight (greater the weight, greater the distance to stop). Grade level and type of surface of path being traveled. Condition and type of tires used. Condition of the brakes. Moisture, ice, or other substances on travel surface.
Page 14 Tip Over Situation (sit down rider): Solidly grab the steering wheel. Brace your feet on the floor (not the pedals). Lean forward and away from the ground. (Stand-up riders), step off the machine.
Page 14 Traveling Safety, you must: Never drive up to anyone in front of a fixed object. Never allow anyone, to walk or stand under a raised boom or forks. Never allow additional riders on forklift. Keep arms and legs inside the truck. Make sure headroom is sufficient. Keep forks as low as possible. Ensure adequate lighting. NO!
Page 18 Operators Manuals Safety Rules: The operator must understand the importance of the operator’s manuals that come with all forklifts from the manufacturer. Remember, it is the operators responsibility to have read and understood the operators manual on that model of forklift prior to operating it (after appropriate training of course)!
